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 Single Aisle 

 TECHNICAL TRAINING MANUAL 


 RAMP & TRANSIT COURSE - M03 (CFM 56) (Level 2&3) 
 HYDRAULIC POWER 
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Single Aisle TECHNICAL TRAINING MANUAL

HYDRAULIC POWER
Hydraulic Power System Line Maintenance (2) . . . . . . . . . . . . . . . . . 2
Hydraulic System Users (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Circuit Identification and Routing (2) . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic Reservoir Filling Presentation (2) . . . . . . . . . . . . . . . . . . . 42
MAINTENANCE PRACTICE
Reservoir Depressurization/Pressurisation (2) . . . . . . . . . . . . . . . . . . 44
Reservoir Filling (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


An interlock mechanism will only permit RAT stowage if the blades
SYSTEM OVERVIEW are properly aligned.
It also prevents rotation when stowed. The interlock will release at
On the green system the normal source of pressure is the Engine Driven
approximately 5 degrees from the full extension position.
Pump (EDP) and as auxiliary source the Power Transfer Unit (PTU).
Extension is by spring force. Retraction (stowage) is by blue hydraulic
On the blue system the normal source of pressure is the electrical pump
pressure.
(E-Pump) and as auxiliary source the Ram Air Turbine (RAT).
Up lock release is by solenoid operation.
NOTE: The blue electric pump can be used as an auxiliary power source Down lock release is by hydraulic pressure.
for maintenance purposes on ground.
On the yellow system the normal source of pressure is the EDP and as
auxiliary sources the PTU and the electric pump (E- Pump).

NOTE: The yellow system also has a hand pump dedicated to cargo
door operation.
PTU
The PTU is an auxiliary pressure supply for either the green or yellow
systems without transfer of fluid between the two systems.
It operates automatically if there is a delta pressure of 500psi between
the green / yellow or yellow / green hydraulic systems.
The side operating as a pump will take fluid from its associated
reservoir and provide an output through the PTU manifold to the HP
manifold.
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The motor side is supplied from the HP manifold through the PTU
manifold, and is connected to the return system. The PTU is
de-activated by closing the solenoid valves on the PTU manifolds.
Each section of the PTU has a case drain connection to the return
system.
RAT
The RAT is an auxiliary pressure supply for the blue system, and for
the emergency electrical power Constant Speed Motor/Generator
(CSM / G). It can be deployed automatically or manually depending
on the failure conditions. The RAT is locked when extended.
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SYSTEM OVERVIEW - PTU & RAT

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


SERVICING
RESERVOIR AIR PRESSURIZATION
All three reservoirs are pressurized to 50 psi to prevent pump
cavitations.
The non-return valves in each reservoir supply manifold, make sure
that the pressure will be maintained for up to 12 hours after engine
shutdown on ground, and for up to 3 hours following a failure of the
air supply in flight.
Each reservoir has a depressurization valve on its associated service
panel. For long time depressurization, a depressurization tool may be
installed on the depressurization valve.
A 77 psi pressure relief valve is installed onto the supply manifold at
each reservoir.
All tree reservoirs are pressurized from Engine 1 for normal supply
and the bleed air system for alternate supply at 43 psi.
The air pressurization manifold has a ground supply connection.
It is put into the blue hydraulic bay and regulates normal or ground
supply to 50 psi.
There are two water drains, one is automatic after engines and APU
shut down, and the other is manually operated.
After maintenance on the hydraulic system, the reservoir pressurization
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can be done via a pneumatic ground cart connected to the reservoir


pressure unit, the APU, or the pneumatic system ground connection.

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SERVICING - RESERVOIR AIR PRESSURIZATION

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


SERVICING (continued)
FLUID LEVEL CHECK
The following Aircraft Configuration is needed for a correct fluid
level check and servicing:
- the speed brakes and spoilers must be retracted,
- the thrust reversers stowed,
- the cargo doors closed,
- all system accumulators empty of fluid and pressurized with nitrogen
to the correct pressure,
- the accumulators pre-charge pressure must be checked,
- the reservoirs pressurized with air,
- the landing gear must be in down position with the landing gear
doors closed (one door may be open),
- and the brake accumulator may be pressurized with fluid.
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SERVICING - FLUID LEVEL CHECK

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SERVICING (continued)
RESERVOIR FILLING
Switch on the yellow electric pump to make sure that the brake
accumulator is pressurized, then switch the pump off.
Connect the selected servicing source to the green servicing panel.
When the panel hand pump is used, connect the hose to the hand pump
and insert it into the fluid container, and then install the pump handle.
The handle is stowed at the yellow servicing panel.
When the external pump is used, connect the lower filling port and
set the minimum flow, do not exceed 435 psi.
Then select the reservoir to be filled, confirming associated light is
ON, and fill with fluid to the upper end of the scale.

NOTE: Over filling the reservoir will result in an inadequate


pressurization.
The reservoir level is also affected by large changes in ambient
temperature. For every 10 °C change, the green and yellow volumes
change by 0.50 l, the blue volume changes by 0.25 l.
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SERVICING - RESERVOIR FILLING

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SERVICING (continued)
BLEEDING
If you have filled the reservoir after:
- maintenance,
- or removal/installation of large hydraulic components,
- or hydraulic fluid low level (loss of the hydraulic system),
- or high loss of hydraulic fluid,
Do the related bleeding procedure to make sure that the quantity of
hydraulic fluid in the system is correct.
After maintenance of the hydraulic system upstream of the EDP,
loosen the nut of the case drain hose so that the air (or hydraulic fluid
mixed with air bubbles) comes out of the connection. Check:
- make sure that the air pressure in the reservoir of the associated
hydraulic system is not less than 50 psi (if necessary, pressurize the
reservoir),
- read the gauge of the associated reservoir and make a note of the
fluid level,
- depressurize the reservoir of the associated hydraulic system,
- after 5 minutes, read the gauge again and make a note of the level,
- compare both levels,
- if the difference between both levels is more than 2 liters, do the
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bleeding procedures again until the result is satisfactory.

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SERVICING - BLEEDING

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SERVICING (continued)
HIGH PRESSURE (HP), CASE DRAIN, AND LOW
PRESSURE (LP) FILTERS
The Hydraulic Systems have:
- a HP filter in the pressure line, in the reservoir filling system, and
the normal braking system,
- an LP filter in the return line,
- a case drain filter in the case drain line of the EDP's and the blue
electric pump.
All these filters have a red clogging indicator, which pops out when
the filter is clogged (dirty).
The LP filters have replaceable filter elements and a by-pass system.
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SERVICING - HIGH PRESSURE (HP), CASE DRAIN, AND LOW PRESSURE (LP) FILTERS

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SERVICING - HIGH PRESSURE (HP), CASE DRAIN, AND LOW PRESSURE (LP) FILTERS

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


SERVICING (continued)
ACCUMULATORS
Each system has an accumulator, located in its associated hydraulic
bays.
The yellow brake system has an accumulator for emergency braking
and parking brake.
The nitrogen pre-charge is adjusted at the accumulator in accordance
to the ambient temperature.
On system pressurization the accumulators will each take
approximately 1 Lt. of fluid.
Each accumulator has a nitrogen pressure indicator.
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SERVICING - ACCUMULATORS

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


SERVICING (continued)
EXTERNAL LEAK TEST OF COMPONENTS
A leak is the quantity of fluid that comes out of a component and that
is sufficient to become a drop or drops, or will possibly become a
drop of approximately 20 drops =1 cc, and 75600 drops =1 gallon.
A leakage is a quantity of fluid on the surface of a component that is
not sufficient to become a drop.
A stain is an area on the surface of a component that has a different
color. It is usually caused when fluid leakage becomes dry on the
component surface after a high temperature operation.
For a correct analysis of component leak rates, you must obey the
subsequent steps:
- the seal obtained at hydraulic tube connections is obtained on
metal-to-metal surfaces. If a leak cannot be stopped by tightening the
nut to the specified torque, the joint is probably defective and should
be repaired.
- when possible, activate components for some cycles before carrying
out the external leakage check.
- dynamic seals are easy to examine for leakage while in the static
condition because pistons, slide valves and swivel joints move only
during a short time interval. Many components cannot be obviously
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monitored during operation.


- by following the AMM procedure operate the related component,
- after operation, inspect the component. If there is a sign of any
external leakage, compare the quantity of leakage with the values
given in the AMM table for specified limits.

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SERVICING - EXTERNAL LEAK TEST OF COMPONENTS

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DAILY CHECKS
During the daily check the reservoirs quantity indication on the ECAM
display unit has to be checked.
In case of incorrect findings during this check, the related AMM tasks
have to be done to restore the system to normal status or to readjust
quantities and pressures to nominal values.
In case of hydraulic fluid level find below normal, the system needs to
be refilled using the Hand Pump or a Hydraulic Service Cart.
In case of hydraulic fluid level find above normal, the system needs to
be drained.
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DAILY CHECKS

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


MEL/DEACTIVATION
The fluid quantity has to be checked on the reservoir direct reading gage
prior to each flight.
The LO LVL Warning has to be checked operative before the first flight.
The air pressure has to be checked on the reservoir direct reading gage
prior to each flight.
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MEL/DEACTIVATION

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


MAINTENANCE TIPS
PTU
PTU inhibition is achieved by closing the solenoid valves (they are
fail safe open) at the PTU manifolds, and for maintenance actions by
also disconnecting the coupling on the yellow (right) side of the unit.
The PTU operation is inhibited at first engine start and during cargo
door operation.

NOTE: At the second engine start, the inhibition is removed when


the second engine master switch is set to ON then the PTU
will operate momentarily for self test purpose.
RAT
The RAT can be tested on ground by using the Ground Check Module.
A RAT retraction module controls the RAT stowage procedure, it is
located on the blue servicing panel.

NOTE: To avoid any extension during maintenance work a RAT


safety tool must be installed.
SAFETY PRECAUTIONS
To prevent an unwanted operation of the PTU, the isolation coupling
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must be disconnected.
Keep the RAT extension area clear of ground equipment and
personnel. Install the RAT safety device before working in the RAT
area.

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MAINTENANCE TIPS - PTU ... SAFETY PRECAUTIONS

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


MAINTENANCE TIPS (continued)
TIGHTENING TORQUES
Before you torque a component or connection, obey the precautions
and procedures given in the tightening practices for hydraulic
connection procedure in the AMM Chapter 20.
The tightening torques are given in the AMM tables chapter 20.
When you use an adapter, the values shown on the dial of the torque
wrench are not the applied values .To get the correct value, the formula
given on the next picture must be applied.
The drawing shows as an example the tightening torque for
HARRISSON and PERMASWAGE sleeve nuts and in-line-check
valves and how to use a torque wrench and adapter.
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MAINTENANCE TIPS - TIGHTENING TORQUES

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


MPD CHECK ITEMS
During the scheduled check (MPD):
- the fluid level on the main hydraulic reservoir indicators has to be
checked,
- the air pressure of main hydraulic power reservoir has to be checked
using the reading gage,
- the clogging indicators on Engine Driven Pump (EDP) case drain filter
(pop out not protruding) have to be checked,
- the nitrogen charge pressure on hydraulic power Accumulators has to
be checked using the direct reading gage.
In case or incorrect findings during these checks, the related AMM tasks
have to be done to restore the system to normal status or to readjust
quantities and pressures to nominal values.
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MPD CHECK ITEMS

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HYDRAULIC POWER SYSTEM LINE MAINTENANCE (2)


ENVIRONMENTAL PRECAUTIONS
Do not discharge products such as oil, fuel, solvent, lubricant either in
trash bins, soil or into the water network (drains, gutters, rain water, waste
water, etc...).
Sort waste fluids and use specific waste disposal containers.
Each product must be stored in an appropriate and specific cabinet or
room such as a fire-resistant and sealed cupboard.
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ENVIRONMENTAL PRECAUTIONS

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HYDRAULIC SYSTEM USERS (2)


GREEN, BLUE, YELLOW USERS
The three independent hydraulic systems respectively supply the users
indicated on the diagram. Between these systems, the users are shared in
order to ensure the aircraft control, even if only one hydraulic system is
inoperative. On the blue hydraulic system, the Constant Speed
Motor/Generator (CSM/G) is used to provide aircraft electrical power in
case of emergency.

PRIORITY VALVES
In the event of low hydraulic pressure, the priority valves maintain the
operation of essential systems by cutting off hydraulic power to heavy
load users.
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GREEN, BLUE, YELLOW USERS & PRIORITY VALVES

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CIRCUIT IDENTIFICATION AND ROUTING (2)


PIPE ROUTING
The A/C has three hydraulically independent systems: blue, green, yellow.
There are no hydraulic pipes in the passenger cabin or flight compartment.
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PIPE ROUTING

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CIRCUIT IDENTIFICATION AND ROUTING (2)


PIPE IDENTIFICATION
Each pipe is identified by a self-adhesive label, which indicates:
- the part number of the pipe,
- the identification of the pipe as a hydraulic pipe, its function with black
dots and the direction of the fluid flow with yellow and blue fields,
- an identification of the system comprising a color code and a number
1, 2 or 3 respectively indicating the Green, Blue, or Yellow system.
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PIPE IDENTIFICATION

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CIRCUIT IDENTIFICATION AND ROUTING (2)


COMPONENT IDENTIFICATION
Each hydraulic component is identified by a placard affixed on the
structure near to it, which gives its Functional Item Number (FIN) and
its designation.
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COMPONENT IDENTIFICATION

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CIRCUIT IDENTIFICATION AND ROUTING (2)


CONNECTIONS
The most common connections in the hydraulic system are shown below.
There are two types of connections:
- permanent connections or permaswage,
- removable connections or standard straight or special fittings.
The manifolds have bobbin type connections for some components. The
bobbins are equipped with a square seal on the component side and an
O-ring on the manifold side.
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CONNECTIONS

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Single Aisle TECHNICAL TRAINING MANUAL

HYDRAULIC RESERVOIR FILLING PRESENTATION (2)


the three colored lights. The direct reading gages are used if no electrical
COUPLING SOCKET power supply is available.
The coupling socket is used to fill the reservoir from a pressurized ground CHECK VALVE
hydraulic supply. The coupling socket includes a check valve.
The hydraulic fluid is sent to the reservoirs via a check valve and the
RESTRICTOR filter of the low-pressure return circuit. The check valves isolate the main
hydraulic systems from the reservoir filling system when it is not in use.
A restrictor located between the coupling socket and the reservoir filling
selector valve protects the system against over pressure.

HAND PUMP
The hand pump is used to refill the reservoirs if no ground cart is
available. The hand pump lever is on the yellow ground service panel.
A specific filling valve including a filter and a check valve is installed
on the hand pump.

FILTER
The filter of the reservoir filling system is equipped with a clogging
indicator.

NOTE: Note: No bypass possibility on this filter.

RESERVOIR FILLING SELECTOR VALVE


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The reservoir filling selector valve directs the hydraulic fluid from the
supply source to the reservoir of the selected system. Do not depressurize
the hydraulic reservoir to refill it. In the NEUTRAL position, an internal
thermal relief valve protects the selector valve from thermal expansion
of the fluid.

RESERVOIR QUANTITY INDICATOR


A reservoir quantity indicator allows refilling monitoring. It shows the
contents of the selected hydraulic reservoir that is indicated by one of
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COUPLING SOCKET ... CHECK VALVE

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RESERVOIR DEPRESSURIZATION/PRESSURISATION (2)


WARNING

WARNING: PAY ATTENTION TO PROTECT YOUR HANDS AND


YOUR FACE FROM THE AIR WHICH COMES OUT
WHEN YOU OPEN RESERVOIR MANUAL
DEPRESSURIZATION VALVES. THE AIR MAY BE
HOT AND CONTAIN HYDRAULIC FLUID. USE
APPROPRIATE SAFETY WEAR.
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WARNING

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RESERVOIR DEPRESSURIZATION/PRESSURISATION (2)


DEPRESSURIZATION OPERATION
You can depressurize each hydraulic reservoir independently. Lets take
the blue hydraulic system. Here is the blue reservoir access door. Open
the blue ground service panel. Do not forget to open, safety and tag the
C/Bs. To depressurize the hydraulic reservoir, we can use the ground
equipment or not. If not, on the ground service panel, turn the cap
assembly of the reservoir depressurization valve clockwise through 90
degrees. Pay attention to protect your hands and your face from the air,
which comes out when you open the manual depressurization valves of
the reservoirs. The air can be hot and contain hydraulic fluid. Listen if
all of the air has been released. The pressure drops down as you can see
on the air pressure gage of the reservoir.

NOTE: A special tool for A300, 310, 320 family, 330 and 340 can also
be used. When connected, the corresponding reservoir stays
depressurized to prevent accidental re-pressurization.
First depressurize the reservoir using the manual depressurization valve
as shown before. Then remove the cap assembly and connect the tool on
the valve. Put the other hand of the tool in a container. Leave the tool
connected as long as it is necessary. Disconnect it when the maintenance
task is completed. Re-install the manual depressurization valve cap
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assembly. Make sure that the valve is in the CLOSED position. Put the
aircraft in the configuration corresponding to the next operation.

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DEPRESSURIZATION OPERATION

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RESERVOIR DEPRESSURIZATION/PRESSURISATION (2)


PRESSURIZATION OPERATION
To pressurize the reservoir, make sure that the depressurization valve is
closed.

NOTE: Note that the three hydraulic reservoirs are pressurized through
the air pressure manifold, thus they are pressurized at the same
time.
Open the blue hydraulic compartment door to gain access to the air
pressure manifold. Install the Ram Air Turbine safety device to prevent
accidental deployment. Remove the cap from the ground connector.
Connect the pressurizing tool to the ground connector. Turn the nut to
open the ground connector valve. Fill the reservoir with air until 50 psi
is shown on the reservoir pressure gauge. Turn the nut to close the ground
connector valve. Remove the pressurizing tool. Install the cap on the
ground connector. Remove the Ram Air Turbine safety device when the
maintenance operation is completed. Close the C/Bs. Make sure that the
work area is clean and clear of tools and other items and all access panels
are closed.
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PRESSURIZATION OPERATION

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RESERVOIR FILLING (2)


To depressurize the green hydraulic system, make sure the travel ranges
WARNING of the flight control surfaces are clear. But do not depressurize the system
reservoir.
WARNING: IF YOU GET THE FLUID ON YOUR SKIN OR IN YOUR So, stop any supply of hydraulic power to the green and yellow systems
EYES: to the ground connectors.
- FLUSH IT AWAY WITH CLEAN WATER, The MLG doors have been opened. On the overhead panel, set the PTU
- GET MEDICAL AID. pushbutton switch in the OFF position and make sure that the OFF legend
MAKE SURE THAT THE TRAVEL RANGES OF THE comes ON.
FLIGHT CONTROL SURFACES ARE CLEAR BEFORE Put warning notices in position to tell people not to pressurize the
YOU PRESSURIZE/DEPRESSURIZE A HYDRAULIC hydraulic systems.
SYSTEM. Electrical power being available, on the ECAM, check the green hydraulic
FOLLOW THE HYDRAULIC SAFETY PROCEDURES. system pressure shows zero. If not, operate the rudder to reduce the
PRECAUTIONS HAVE TO BE TAKEN BEFORE pressure to zero.
STARTING HYDRAULIC RESERVOIR FILLING Safety and tag the appropriate C/Bs. In the MLG bay, check that the green
OPERATION. MAKE SURE THAT: reservoir pressure and the green accumulator pressure are normal.
- THE SPEED BRAKES AND SPOILERS ARE Now let's fill the green system.
RETRACTED, Go to the ground service panel of the yellow system to remove the hand
- THE THRUST REVERSERS ARE STOWED (CFM-56 pump handle.
ENGINE ONLY), On the other side, open the green ground service panel.
- THE L/G IS EXTENDED AND THE DOORS ARE Notice, that is possible to fill any of three hydraulic reservoirs from one
CLOSED, place.
- THE FWD AND AFT CARGO COMPARTMENT It is also possible to fill the reservoir with the hydraulic service cart,
DOORS ARE CLOSED. connected here.
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So, the hand pump is connected to the shaft of the pump. Above the panel
PRECAUTION you find the filling hose, remove its cap. Remove the blanking cap of the
Servicing procedure to fill up the green hydraulic reservoir. pump, connect the filling hose to the filling valve.
Some precautions have to be taken. Put it other end in a clean container. Turn the selector to the green system
Make sure that the speed brakes and spoilers are retracted, the thrust position.
reversers are stowed, the L/G is extended and the door closed and the Make sure that on the quantity indicator the green light comes on.
FWD and the AFT cargo doors are closed. All the other hydraulic services Operate the pump. Monitor the increase of the fluid level on the quantity
must be in normal position. If not possible, use common sense to read indicator.
the reservoir quantities. If there is no electrical power is available, the fluid level can be checked
on the reservoir itself. Take also into account the outside temperature.

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Stop the flow of the hydraulic fluid when the pointer is almost to the fill
level and adjust the level in accordance with the AMM table.

CAUTION: If some components are not in their normal position, such


as landing gear doors, use common sense during filling, in
order to avoid under or over servicing.
Turn the selector back to the NEUTRAL position.
On the quantity indicator, the green light goes out.
If a reservoir is overfilled, you cannot pressurize it correctly
and you must drain it. Remove the filling hose and re-install
the blanking caps.
Put the filling hose back in its cap position.
Remove the handle from the hand pump and put it in its cap
position of the yellow service panel.
Close the ground service panels.
On the overhead panel, set the PTU pushbutton switch to
the AUTO Position and make sure that the OFF legend goes
OFF.
C/Bs closed, L/G doors closed.
The work area is clear.
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WARNING & PRECAUTION

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AIRBUS S.A.S.
31707 BLAGNAC cedex, FRANCE
STM
REFERENCE UAF09471
NOVEMBER 2009
PRINTED IN FRANCE
AIRBUS S.A.S. 2009
ALL RIGHTS RESERVED

AN EADS COMPANY

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